Parts Packaging

ABSTRACT

A packaging product and method of packaging items by using a flat stiff board having the general shape of each part to be bundled cut into the board. Preferably the board is joined with another backing board, the parts are placed within the cutouts, transparent tape may be optionally applied over one or more of the parts and a transparent wrap is placed over the board.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/718,704, filed Oct. 25, 2012.

BACKGROUND

Often small parts are needed to be bundled in desired quantities and assortments as “kits” for use at a later time, such as when needed for installation, assembly or repair of a device, including engines and turbochargers and may include small engine parts, rubber and metal gaskets, o-rings of all sizes, bolts, washers, and screws. When the end user is performing a given task upon the device, the appropriate kit, with the bundled parts needed, may be obtained and used, ensuring the proper parts are removed and replaced.

The parts are often bundled in a convenient container, such as a bag or envelope. Frustration can result, however, when the end user of the bundled package finds that a part was inadvertently left out or lost during bundling of the parts or storage. Even with clear plastic bags or envelopes, it is difficult for a person to quickly assess whether all parts intended to be bundled in the container are present. Bags or containers also present storage and inventory difficulties in that they generally do not stack well when placed upon a shelf or within another container and making it difficult for a person to quickly count the number of bundled parts containers present in a given location. A need exists for an inexpensive packaging product and method of packaging small parts whereby the parts are easily packaged, compactly stored, easily viewed for inspection and identification, and easily removed for use when needed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is illustrated by the accompanying drawings, which exemplify the invention but do not limit the invention's scope, in which:

FIG. 1 shows a completed packaging container with parts and outer wrapping installed.

FIG. 2 shows a front view an embodiment having a single fold.

FIG. 3 shows an overhead view of an embodiment having two folds.

FIG. 4 FIG. 3 shows a front view of an embodiment having two folds and providing added depth to one cut-out recess.

FIG. 5A shows a front view of an embodiment having a single fold.

FIG. 5B shows a front view of an embodiment having a single fold, the part recesses possess added cut-out sections for ease of removal of the parts.

FIG. 6 shows a front view of an embodiment having two folds and providing added depth to one cut-out recess and an additional cut out on the rear panel.

FIG. 7 shows a front view of an embodiment having two folds and providing added depth to one cut-out recess.

FIG. 8 shows a front view of an embodiment having a single fold, the fold being intermittently scored to provide ease of folding.

FIG. 9 shows a front view of an embodiment having a single fold, the fold being intermittently scored to provide ease of folding.

BRIEF DESCRIPTION

Disclosed is a packaging container designed to remedy the problems with traditional bundled parts containers. In one embodiment a flat stiff board is disclosed having the general shape of each part to be bundled cut into the board. In another embodiment the board is joined with another backing board, providing additional stiffness and preventing parts from falling through the back side. The parts are placed within the cutouts and a transparent wrap is placed over the board.

In another embodiment the board is folded over once for single panel and glued together to form a compartment or special shape recess for each part to fit in. The board may be folded twice for double panel thickness to form a deeper compartment or a special shape recess for thicker parts. When the boards are assembled and glued, the parts, such as a bolt or o-ring, may be placed in the custom shaped recess in the board.

The board may be made from corrugated paperboard material, folding carton materials or plastic core materials. The board is then customized by creating apertures, such as by die-cutting, with the desired part-fitting shapes. A transparent covering, such as a shrink-wrap film, may be placed over the board.

Each kit can be custom die cut and designed according to the parts needed. In an embodiment each die cut board is cut to fit each part such that the part has an interference fit with cut-out shape of that particular part. Some finger sized portions, or interconnecting spaces between each part may be cut-out of the board to allow easier removal of each part. Each kit then may be wrapped with a clear shrink wrap film. The thickness of the film can vary depending upon number and weight of parts on kit die cut board, but usually between 75 mil.-100 mil. The resulting bundled kit packaging enables inspectors, assembly line workers, or end users to identify any wrong or missing parts. The easily viewable kit contents enables the assembly line to visually have a 100% quality check system in place to stop bad or incomplete kits from leaving the plants, reducing end-user and customer frustration, down time and costs.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a completed packaging container 1 with parts and outer wrapping installed. The top layer 5 of the board possesses a plurality of cut-outs 31 forming recesses. The board has a bottom layer that was folded and bonded to the top layer 5 at a folded edge 21. The folded edge has a scored portion 22 and a hinge portion 23. The hinged portion 23, being un-scored or incompletely scored, attaches the top layer 5 to the other layer or layers.

FIG. 2 shows a front view of an open unfolded die cut design for an embodiment having a single fold 21. Here, a plurality of apertures 31 having the general outline shape of the part that fits within them are present in half of the board. The fold 21 may be intermittently scored to allow it to crease easily and precisely when folded. Alternatively, the fold 21 may be scored partially though the upper portion of the board allowing the board to crease easily and precisely when folded.

FIG. 3 shows an overhead view for an alternate embodiment having two folds. The top layer portion 5, spanning from the first fold 21 to the opposing adjacent edge 4, possesses a plurality of cut-out portions 31 sized appropriately to receive each part. In this embodiment, the cut-out portions are slightly undersized to cause an interference fit with each part for part retention within the board 1. Each fold 21, 25 possesses a scored section 22 and a hinged section 23. The hinged section allows each layer to remain attached and accurately fold against another layer. Hinge cuts 24 cut perpendicular to the fold 21, 25 prevent tearing of the board along the hinge sections 23 and otherwise aid in the folding of the board. A middle layer portion 7, positioned between the first fold 21 and second fold 25, possesses a single aperture 51 to aid in the removal of a part positioned in the aperture of the top layer portion. A bottom layer portion 9, positioned between the second fold 25 and the opposing adjacent edge 10, possesses a single aperture 53. When the board 1 is folded, apertures 51, 53 and an part containing aperture 31 align allowing one to remove a part by insertion of a digit through the apertures 51, 53 from the bottom of the board 1. It should be understood that apertures 51, 53 may be present in a greater number for aiding removal of multiple parts, or alternatively, apertures 51, 53 may be absent.

FIG. 4 shows a front view an embodiment having two folds 23, 25 and providing added depth for one cut-out recess by having a corresponding aperture 35 formed in a second layer. The added depth for the cut out is created by forming an aperture 35 on a second layer 7 which is aligned with the corresponding aperture 33 on a first layer 5 when the board is folded along the fold 21.

FIG. 5A shows a front view of an embodiment having a single fold with apertures 31 placed on only one side of the fold 21. Each aperture 31 is sized and shaped to fit a specific part. The apertures 31 are shaped so that each aperture has the general outline shape of the outline of the corresponding part that fits within it. As used herein, “general outline” means that the geometric shape of the aperture 31 is the same as the two dimensional outline of the part that fits within it, except that the aperture 31 may have finger sized deviations from the outline for ease of removal, or so that the aperture 31 is easier to construct by reducing the amount of curvature of the outline, but otherwise substantially follows the outline of the part while allowing the part to fit within the outline shaped aperture.

FIG. 5B shows a front view of an embodiment having a single fold, the part recesses possess added cut-out sections 41, 43 for ease of removal of the parts. The additional cut out section may be in the form of additional material removed 43 between the recesses used to hold the parts. The additional cut-out sections may be removed finger holds 41 around the die-cut sections used for a single part.

FIG. 6 shows a front view of an embodiment having two folds and providing added depth to one cut-out recess 33, 35 and an additional cut out on the rear panel 37. This embodiment demonstrates how both sides of the board may be used for holding parts.

FIG. 7 shows a front view of an embodiment 1 having two folds 21, 25 and two apertures 71, 73. When the apertures 71, 73 are aligned after folding along the first fold 21, and the bottom layer portion 9 is folded, a deeper recessed compartment is obtained for holding a single part.

FIG. 8 shows a front view for an embodiment 1 having a single fold 21, the fold 21 being intermittently scored to provide ease of folding.

Once the layers of the board are bonded to one another, the parts may be placed within the cut out recesses of the board. Transparent tape, such as a clear polyethylene protection tape, may be placed over the part and recess. The tape acts to secure the part in place, preventing it from pushing through the clear wrap. The additional layer tape is an optional step, and can allow the use of thinner shrink wrap to contain lighter parts, while supporting the heavier parts with the additional layer of tape. The tape may be placed over the part after any previous step of placing a part within the respective recess, but before the board is wrapped with a transparent or translucent wrap.

The board may then be wrapped with a plastic shrink wrap. The shrink wrapped board may be placed into a warm oven to allow the shrink wrap to tighten.

The result is a parts package that is easy to visually verify the presence or absence of a part, aiding in efficiency of the quality control. 

We claim:
 1. A flat package having a plurality of recesses for a plurality of parts contained therein comprising: a board having a first layer and a second layer; a transparent plastic wrap; said first layer having a plurality of apertures, each said plurality of apertures having a shape matching the general outline of each said part; said second layer bonded to said first layer; wherein said parts are placed within each aperture and said board is wrapped with a transparent plastic.
 2. The packaging of claim 1 wherein each said aperture forms an interference fit with each part.
 3. The packaging of claim 1 wherein said first layer and said second layer are joined at a folded edge.
 4. The packaging of claim 1 wherein said first layer and said second layer's folded edge possesses a scored portion and a hinge portion, each said hinge portion being between two hinge cuts, each hinge cut made perpendicular to the folded edge.
 5. The packaging of claim 1 further comprising a third layer, said third layer bonded to said second layer.
 6. The packaging of claim 1 further comprising clear tape placed over at least one said part and under said transparent wrap.
 7. The packaging of claim 1 wherein said board is corrugated paperboard.
 8. The packaging of claim 1 wherein said board is plastic core material.
 9. The packaging of claim 1 wherein said board is folding carton material.
 10. A method of packaging a plurality of parts in a flat package having a recess provided for each part contained therein, the method comprising: selecting a board of a desired thickness; partially cutting said board where said board is to be folded forming a cut fold line; cutting at least one shape outline, said shape outline being cut in the general shape of the outline of at least one said plurality of parts; folding said board over said cut fold line; placing said each part within each respective shape outline; placing transparent tape over said each said part; and wrapping said board with a transparent plastic.
 11. The packaging of claim 10 wherein each said shape outline forms an aperture having an interference fit with each part.
 12. The packaging of claim 10 wherein said board is corrugated paperboard.
 13. The packaging of claim 10 wherein said board is plastic core material.
 14. The packaging of claim 10 wherein said board is folding carton material.
 15. The packaging of claim 10 wherein at least a portion of material adjacent to one said shape outline is removed forming an enlarged shape outline, allowing for a finger of a user to extend down into said enlarged shape shape outline and alongside said part.
 16. A method of packaging parts in a flat package having a recess provided for each part contained therein, the method comprising: selecting a board of a desired thickness; partially cutting said board where said board is to be folded; cutting at least one shape outline, said shape outline being cut in the general shape of the outline of said each part; a portion of material adjacent to one said shape outline is removed forming an enlarged shape outline, allowing for a finger of a user to extend down into said enlarged shape outline and alongside said part; folding said board along said fold line; placing said each part within each respective cut-out; placing transparent tape over said each said part; and wrapping said board with a transparent plastic.
 17. The packaging of claim 16 wherein said board is corrugated paperboard.
 18. The packaging of claim 16 wherein said board is plastic core material.
 19. The packaging of claim 16 wherein said board is folding carton material. 